Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

A welding system including a fine tuning knob and a coarse adjustment knob for setting a weld wire feed speed are provided. The welding system may include a welder having the coarse adjustment knob and a spool gun having the fine tuning knob. A user may adjust the knob on the welder to set a coarse adjustment wire feed speed and may adjust the knob on the spool gun to fine tune the wire feed speed setting.

A system and method of welding is provided where at least two welding electrodes are provided to and passed through a single orifice on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes.

A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

The invention relates to a monitoring module (1 . . . 1″) for monitoring an electric arc machining process, the module comprising a camera (2), a photo flash lamp (3) and a control system (4) that controls the photo flash lamp (3) and a control system (4) that controls the photo flash lamp (3) in such a way that it illuminates when the camera (2) records the image. According to the invention, the components (2, 3, 4) are arranged in a common housing (5).

A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

The present application discloses an electric welder, and relates to a field of an electric welding equipment. The electric welder includes a shell, a welding barrel, a controller and a welding wire feeder; the shell includes a handheld part, and the welding barrel, the controller and the welding wire feeder are installed in the shell; the welding wire feeder is configured for conveying the welding wire into the welding barrel; the controller is configured for controlling a start and a stop of the welding wire feeder and an arcing of the welding wire. The welding barrel, the controller and the welding wire feeder are installed in the shell to form an integral structure, which makes the welder more convenient to carry. In addition, by providing the welding wire feeder, a frequent replacement of the welding rod during a welding process is reduced, and the overall operation is more convenient.

A 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. An electrode wire can supply energy to the weld pool while being fed at a first feed rate into the weld pool. A second wire can be fed into the weld pool at a second feed rate to deposit additional material and thereby speed up the overall material deposition rate. All of the energy in the weld pool may be supplied by the electrode wire. The printer can dynamically control the first feed rate and the second feed rate during printing. A mathematical model can be used to determine the second feed rate as a function of the first feed rate, the energy put into the weld pool, and the print head travel speed. The second feed rate may optimize the material deposition rate according to the model.

A method for providing a referenced distance signal which corresponds to the distance between a contact tip of a welding torch and a workpiece to be machined, includes adjusting an operating point on a predetermined welding characteristic, which is defined at least by a wire feed rate, a welding voltage and/or a welding current, and a CTWD distance between the contact tip and the workpiece; determining a target parameter value of at least one parameter dependent on the CTWD distance for the operating point; determining an actual parameter value of the at least one parameter by measuring at least one of the present wire feed rate, welding voltage and/or welding current; modifying the determined actual parameter value as a function of a calculated difference between the target parameter value and a predetermined reference value; and outputting the referenced distance signal corresponding to the modified actual parameter value to a position control system of a robot arm.